If you manufacture packaging machines and want to increase your profitability, then we can help: with a complete range of services and products designed to increase your machine’s speed, versatility, performance and safety.
Although some of these packaging machine solutions are highly advanced, they are also proven to be extremely reliable, to maximise your customers’ loyalty.
Use our knowledge as a specialist automation partner to develop a new machine or upgrade an existing model.
Your speciality – our specific expertise
Are you a specialist in bottling? Or perhaps you focus on snack foods? Do you manufacture primary packaging machines or do you offer secondary and final packaging machines as well? Whatever your speciality, we can discuss with you about increasing your profitability in packaging in any of the following sectors:
- Bakery & biscuits
- Beverages (alcoholic, non-alcoholic, dairy, oil &CSD)
- Cosmetics & healthcare
- Dry food & snacks
- Fresh food
- Homecare & other
- Liquid & canned food
- Ready meals
Even before the end-product is wrapped, canned, bottled or bagged, many packaging machine builders take time to consider their customers operations from start to finish.
The repeatability of operations with high productivity and high quality standards is a daily challenge.
That’s why Omron offers a wide product portfolio adapted to recipe-driven batch production, this requires technologies such as high-speed, high-resolution multi-loop regulation control, high-speed data processing and storage as well as seamless vision-based quality inspection.
Speed is the main challenge here. But there is also a need for
- product batch size independence
- easy-to-clean and easy-to-operate machines
- maintaining hygiene standards.
This unique combination empowers you to phase-out conventional mechanical systems, and replace them with highly versatile Delta-robot and vision systems.
The key challenges here are:
- to match the production speeds of the primary packaging
- to ensure individual pack or multi-pack integrity
- to ensure easy adaptation of linear guides to convey both primary and secondary packages.
Omron solutions help you build more flexibility into your machines. We can provide the latest robotics and vision systems to help create, for example, robotic cartoners that pick and load 12 products simultaneously, using a pack pattern of either one, two or three layers.
With a set-up like this, increasing the speed is simply a question of increasing the number of products picked per operation.
The main challenge here is to ensure that high loads can be reliably handled at continuous high cycle frequencies.
Omron solutions include a wide range of highly robust electromechanical linear axes. Ready-to-install linear modules with different drive variants and turn/gripper modules complete the fully equipped handling modules.
The ability to use electric actuators in any combination also increases the versatility for cost-effective adaptations.
In an HFFS machine a flexible web/foil is unwind, the packs shaped and then sealed on 2 sides, optionally the bottom too. After filled vertically with product, the top side is then sealed to closed the pack. Optionally before the final seal is made, a spout can be added. This all happens with the flexible packaging material moving horizontally, but with the pack orientation still vertical. The picture below shows an intermediate operating, cam driven machine. Also continues machines exist, with these the sections 4 till 6 are often in a carousel set-up.
Rotary sealing knifes (servo driven)
Gantry robot palletisers are linear, cartesian (XYZ) coordinated robots for pick and place applications. The axes slide linearly in relation to each other, rather than rotate as with a robotic arm.
The machine comprises a robot mounted on a frame which overlaps two feeding conveyors running in parallel. One conveyor is feeding the products and another the cartons. The robot picks the products randomly moving on the conveyor belt and places them into the moving cartons. The instantaneous location of moving products is computed by the vision system acquiring images from a stationary camera. Meanwhile a registration sensor is used to track the position of the cartons. This is the accurate tracking of both conveyors which enables the robot to pick and place products from one running conveyor to another.
Shrink sleeve labels are supplied from a roll in the form of a continuous web, unlabeled bottles are transported via an infeed conveyor and then metered via a rotating feedscrew. While the bottles enter the labeler moving past a trigger cell, the labels in web form are opened and formed into a tube by a mandrel, fed and cut in precise registration with a printed graphic, applied to a bottle which is then conveyed up to a steam tunnel.
Empty trays are loaded by a tray denester on the infeed line and conveyed up to the sealing station. The sealing operation consists in welding a thermoplastic film on the edges of the trays, the operation being performed in a vacuum or in a neutral gas atmosphere. Before any sealing operation, a new length of film is unwound, positioned over the trays, welded on the edge of the trays and excess film wound again on a scrap roll.
GriPS Automation GmbH and D&T engineering GmbH have developed a solution to streamline pipetting, reducing processing time from one hour to ten minutes per plate.
Based in Italy, Martini Srl produces high-precision weighing and packaging machines for the food sector. Its new MCRS-VD packaging system enables the packaging of up to 180 packs of pasta per minute. At the heart of the solution is an OMRON NX701 1600 machine controller. This manages the movements of the MCRS-VD. OMRON’s NX-TC Perfect Sealing technology enables the end user to improve the stability of the thermoregulation involved and reduces the costs associated with the use of packaging films.
OMRON and Reitec join forces to create the new RC-1 cobot palletiser solution
Collaborative robot carries out intelligent labelling on different product formats - reducing downtime due to format changes by up to 70% - in a solution developed by Bluengineering for Gruppo Romani in Italy.
Large companies are increasingly turning to robotics to streamline manual processes in factories and warehouses. One example is Diva International, based in Umbria, Italy. Diva wanted to transform its system for transporting wet wipes from its production facility to a palletising island in the same warehouse. Through its facilities management provider, FM Vision, it developed a new, automated system using five OMRON autonomous mobile robots (AMRs) and OMRON’s Sysmac NJ machine controller. This has led to a safer, more efficient and more flexible process.
German medical technology expert Senova cooperated with OMRON and Kraus Maschinenbau GmbH to pioneer the factory of the future.
A guide to the validation of vision systems used in the pharmaceutical industry using Omron components
Machine Automation concepts to enable innovation for digitalized manufacturing
Industrial automation processes, as well as the machines, are becoming increasingly dynamic. The need to increase productivity, flexibility, ergonomics and safety has become indispensable. This white paper describes how the Omron Sysmac Safety solution enables you to meet all possible safety scenarios and requirements.
Good programming practices and well organized software implementations with Omron PLC.
Secure Remote Access to machines through VPN.
Faster and more precise image processing methods and technology
The amount of product recalls leapt up during 2015. Robert Brooks argues that effective and integrated plant automation can play a lead role in minimising those costly and damaging recalls.
Dennis Verhoeven, European Industrial Market Manager, Life Science at Omron, reviews how product personalisation is increasingly important in the food and beverage industry.
The ongoing pursuit of ever better OEE scores has become a real focus for end users in the food and beverage industry in recent years. OEE itself, however, is not a conversation end users routinely have with their machinery suppliers, with the focus instead tending to be on areas such as baseline speed, cycle times and overall performance.
How close is ‘Industry 4.0’ to being a reality? A futuristic, completely-connected industrial world is already taking shape, and data integration is a key enabler. Collecting and storing production data also offers many other rewards – from measuring OEE (Overall Equipment Effectiveness) to helping OEMs meet increasing legal requirements for reporting. Dan Rossek takes a deeper look into the challenges and benefits of data integration in ‘From shop floor to top floor’.
The demand for greater traceability – to reduce counterfeiting and improve consumer information – presents growing challenges for manufacturers. How can serialisation help? In ‘Traceability through serialisation’ Dan Rossek focuses on what serialisation means today and shows why the flexible layer solution is better than the, seemingly easier, end-to-end solution.
Can you add value to your machines, perhaps adding greater sophistication and complexity, without impacting on development time and programming cost? Robert Brooks looks at the evolution of a new breed of machine controllers.
The ramping up of the low wage economies in the machine building sector means that OEMs often feel they are working under the shadow of the threat of cheap imports. In the first of a series of articles, Robert Brooks looks at the ‘must-have’ features that will keep UK machine builders ahead of the pack, and the opportunities to add even greater value.